| This task is a practical production item which comes form Ying Jia technology company. The main job is that judge the quality of the gear spring,thereby enhance the production efficiency and precision。Under analytical study the process flow and controlling require of checkout equitment,ascertain hardware unit,advance control scheme in which PLC with USB is control cored and computer is monitor core .As a result we achieve the automation and visualization of the gear spring checkout equitment.Present clustering analysis with variance of the algorithms by analyzing the data of the manufacturer.Achieve communication between the PLC and computer.Accomplish the analysis store disposal of the field data,thus accurate aftermath can be output.Along with automobile enterprise vigorous development, the automobile lockset development prospect day by day is also broad. Because passenger vehicle's door lock units are small and many, the manual setting is tedious, the efficiency is also low, these can not satisfy the request of volume production. Thus it need to develop the car lock's major component automatic assembly system, adapts to the request of volume production.However, at present, the domestic enterprises that produce auto car lock mainly make the examination methods of the gear spring into two kinds of situations. One kind uses the means of manual test, the other kind uses the means of importing developed countries'Check-out facility in European, such as US as well as Germany and so on. Not only the price of these equipments is expensive, but also the maintenance is difficult, so it does not suit to promote the application in our country. Thus we need develop high accuracy, high efficiency, redundant reliable, low cost, ease of operation, work reliable gear spring check-out facility, it has already became the urgent need in the steam car lock processing industry .Nowadays, science and technology have been developing rapidly, the production life increasingly pursues the high efficiency, this point appears especially importantly in the industrial production, the scientific researchers are also unceasingly renewing the technology of control device to meet the need of thisdevelopment. PLC, as one kind of highly effective, nimble, the reliable controllers, is widely applied.Take the PLC controller as the core, on position PC machine has become a development direction of the industrial automation PLC control system for the real-time monitoring body control system. The former produced PLC and on the position machine carry on the correspondence by the way of RS232 string mouth correspondence, but it already could not satisfy people's request, now we request it to process the mass data, moreover request its timeliness to be strong, so it must enhance the correspondence speed, In recent years,the appearing USB string mouth correspondence may satisfy the request of processing mass data . This topic take OMRON-CP1H PLC as a lower position machine, it carries on the correspondence through USB and the main engine.Studies the principle of PLC and the computer correspondence as well as the realization of PLC and the computer correspondence's design based on Visual Basic6.0 platform, This means of communication have many advantages, such as the composition nimbly, timeliness is strong, the performance price compared to the higher and so on. This topic goal is to complete a set of control system which is unified by PLC and the on position machine, including software and hardware design.This dissertation composes of seven chapters,sum up as follows:1,Detail the components of the control system and the feasibility of the PLC and the PC. After analysis the data and contrast the program determined the control algorithm. The algorithm use the method of combining cluster analysis and variance of this paper can achieve rapid and accurate classification. The algorithm proposed in this paper is based on summarized and analyzed data of the original manufacturers. Before judging the quality, use the torque sensor collect the data, and then, handle the data on PC. Judge the variance first, cluster the components which meet the demands of the variance, otherwise directly judge it as a failed components. Classified according to cluster analysis method to the qualified components, use Euclidean distance divided the qualified components into three parts: Qualified, Excessive torque, Torque too small.2,Design the hardware of this system according to the technology demands of the equipment. After clearing the control demands, we choose the CP1H-XA40DR-A PLC of OMRON Company to be the core control, determined the points of I/O, and choose the IN/OUT module, define the communication interface. Explained the principle of Torque Sensor and stepper motor, determinedthe models of them according to the process requirements and design the circuit.3,Complete the design of the PLC software, painting the flowchart according to all public spaces, make the programming. Detail the design of the software of Torque Sensor and stepper motor.4,Research USB technology and the communication protocol of PLC, realize the communications between a PC and the PLC in platform of the visualization software Visual Basic; complete analysis, handle, storage of the scene data, and can output the control result accurately according to the control algorithm; A friendly human-computer interface make the information exchanged; work of the whole equipment have a better control, Automatic mapping of the torque curve reduce errors, improve the accuracy of judge, use the USB interface realize the parameter passing can complete the demands of control faster and better, set the parameters, realize the function of data storage, and use the fault table can find the fault of its failure in time to resolve.Compared with the pre-production control program, in the following there are three points that have innovative breakthroughs which can play a positive role improve the accuracy and efficiency in the actual production.1, they usually use the RS232 data communications standard in the past. In this paper USB1.1 technology is used for data communications. It can reduce the time of data acquisition and data transfer and improve the detection efficiency of the whole system;2, the system increased the PC's functions, such as monitoring the status of work, data processing, Information on the handling and processing functions of the fault information are all improved, the achievement of good man-machine interaction information. Improve the operability of equipment and the efficiency of the worker.3, the process of measuring has a large number of human factors previously, such as the best value judgment. This paper proposes an algorithm of the combination of the variance and sub-cluster, this algorithm used to reduce the impact of human factors. Improve the quality of judging the accuracy and precision of detection, so that reduce the error rate of equipment.The research shows that this subject satisfies the need of the control completely and satisfies the requirements of the measurement accuracy. In short ,this paper complete the design of electrical control part of the gear Springtesting equipment, reasonable hardware and software design can make all work places will be coordination. It can test the gear wheel spring rapidly and reasonable according to the demands, and it can make the classification. Make it completely replaced the original detection means, avoid artificial testing and the statistical error. Improve statistical accuracy and testing precision. Realize the automation of the testing and statistical management of the gear wheel spring, and the produce the gear wheel Spring testing equipment in China. |
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